Handheld spray receptor

ABSTRACT

The handheld spray receptor provides an apparatus which, when used with a supply of a liquid under pressure, dispenses a liquid material in a pattern that is controlled by an inexpensive and disposable actuator. Such actuators are employed as an industry standard part that would be found on any aerosol spray can, and feature small cylindrical actuators that may be easily interchanged, so as to provide varied spray patterns. A purging model provides for a quick and convenient method of purging liquid from the actuator, so as to prevent hardening of liquid material exposed to the atmosphere, and a subsequent clogging of the receptor. When used with a supply of liquid under pressure and access to a propellant, the handheld spray receptor significantly reduces the amount of hazardous waste, in the form of partially consumed aerosol cans, that would otherwise enter landfills or hazardous waste recycling facilities.

CROSS-REFERENCE TO RELATED APPLICATIONS

This application is a divisional application from application Ser. No.10/179,088 filed 25 Jun. 2002, now U.S. Pat. No. x,xxx,xxx, thedisclosure of which is hereby incorporated herein by reference.

BACKGROUND OF THE INVENTION

1. Field of the Invention

The handheld spray receptor provides an alternative method of dispensingliquids under pressure, as might be alternatively accomplished with anaerosol container, or a traditional spray gun. Traditional aerosol cansoften dispense hazardous materials, and when the actuator or verticalvalve on an aerosol can becomes clogged, the entire can becomes useless,and is often discarded improperly, creating a hazard. Cleaning out theactuator and vertical valve of an aerosol can is difficult and oftenineffective. A purging capability can be approximated with an aerosolcan, but requires expensive equipment specially designed, in mostinstances.

2. Description of Prior Art

The most traditional method of selling and dispensing liquid materialsis by way of the traditional aerosol can. The propellant utilized intraditional aerosol cans is often hostile to living beings, and as suchprovides a hazard to the user of the aerosol can, as well as a pollutantto the environment as a whole. Aerosol cans also provide poor economyfor viscous liquids. Viscous liquids must be thinned with a materialwhich is often detrimental to the user and the environment, such aspaint thinner or methyl alcohol. It is not uncommon for a consumer toreceive an aerosol product with 90% thinner, and 10% product, making theaerosol can an expensive method of delivering product. An aerosol canmay purge the material in the feed tube and actuator button, by holdingthe can upside down and depressing the actuator button, but this cancause the propellant to become exhausted, rendering the aerosol canuseless, even though there may be additional liquid still in the can. Inaddition, the actuator button often becomes clogged, causing theremaining liquid to be unusable. Aerosol cans create a major disposalproblem, when they become empty, and are hazardous materials that mustbe properly handled to be safely disposed of.

A variant of the traditional aerosol can is the aerosol powered foamcontainer, as might be used to dispense shaving cream. These canstypically utilize an actuator that is crimped to the mouth of the can,accompanied by a slot or other large flow opening which releases thematerial rather than spraying it. U.S. Pat. No. 5,027,986 provides anexample of this kind of application. Other mechanisms utilize anextension tube and a piston effect to dispense liquid in a flow, not aspray. U.S. Pat. No. 3,346,194 provides an example of this kind ofdispenser.

Lawn and garden sprayers have been developed which dispense liquidmaterials under pressure. These are often provided with a compressionpump, allowing the operator to pressurize the liquid in the tank, and torelease fertilizer, herbicides, or pesticides (or any other liquid thatmight be useful in gardening) by means of a trigger mechanism. U.S. Pat.No. 5,307,995 discloses an enhanced method of attaching a hose to such asprayer. U.S. Pat. No. 6,278,837 discloses a sprayer with a traditionalvertical action valve assembly. Inventions directed to dispensingpersonal care products perform similar functions. U.S. Pat. No.3,190,502 discloses an invention that will dispense shampoo in acommercial shop, such as a beauty salon or a barber shop. A fixedelectrical pump is used to create pressure on the tank of liquid to bedispensed, and the handheld receptor creates a flow of shampoo, and nota spray of material.

Handheld pump sprayers are available to dispense insecticides, such asthe spray pumps that come attached to ant or roach poison products soldin hardware and lawn and garden stores. The dispensed material istypically carried in one hand, and the other hand dispenses materials bysqueezing the handle in a repeated fashion, so as to cause the liquid tobe dispensed in a spray or a single stream. Such systems have also beendeveloped to dispense cooking oil, or other such viscous liquids. U.S.Pat. No. 5,718,383 discloses a handheld pumping mechanism attached to afeed hose, so that vegetable oil may be sprayed on a cooking surface.The liquid is not under pressure, and the operator provides themechanical energy required to operate the hand pump, thereby controllingthe amount of material dispensed.

A traditional spray-gun, as might be utilized to spray paint, utilizesan air compressor to provide pressure, and typically features acontainer into which the liquid to be sprayed is placed. Some sprayingsystems have been developed specifically for dispensing a measuredamount of material from an aerosol can. U.S. Pat. No. 5,427,281 utilizesa reservoir onto which an vertical action valve assembly is attached.Both a traditional spray-gun and a device with a reservoir have theproblem of cleaning out the residual material upon last use of the day.When used to dispense materials that harden when exposed to air, such aspaint, both the reservoir and the actuator must be purged of material.

U.S. Pat. No. 5,170,939 discloses a handheld paint sprayer which doesnot contain a reservoir, but which provides a special valve whichdirects compressed air through the spray actuator while insuring that nocompressed air causes “backflow” of the liquid intake hoses. Like manyother actuator assemblies, cleaning of the actuator and valve assembliesis time consuming and complicated.

The cleaning of actuators, also referred to as nozzles, can beaccomplished with specialized and dedicated equipment. U.S. Pat. No.6,355,114 B1 demonstrates an apparatus for forcing solvent through oneor more nozzles, and capturing the spray for reuse, or for disposal.When portability is not required, there are a number of inventions whichprovide purging capabilities. U.S. Pat. Nos. 5,803,109 and 6,116,261 areexamples of mechanisms employed in automated paint application systems,as might be found in an automotive assembly plant. These systems employcomplex automation to engage the purge cycle, and are integrated into afactory's equipment.

Large industrial paint systems, which are designed to change the colorof paint applied on a frequent basis, often include a purgingcapability. U.S. Pat. Nos. 3,981,320; 4,232,055; 5,072,881; 3,240,225;and 3,716,191 are examples of large industrial systems designed withpurge capabilities. The purge capability is included to permit a singlenozzle or set of nozzles to be supplied with different colors of paint,without disassembling the equipment for cleaning.

Systems designed to dispense special materials, such as powder paint,also employ purging systems. U.S. Pat. Nos. 6,112,999 and 6,315,214provide examples of systems that dispense special paints, and employ apurging capability. Specialized amine-assisted systems disclosed in U.S.Pat. No. 4,862,196 also employ purging systems to clean the nozzle ofthe mechanism.

The prior art provides solutions for the casual consumer, such as atypical homeowner, and for the major industrial factory. The consumer ona shop floor, such as a maintenance depot, finds aerosol cans to behazardous, ineffective, wasteful, and expensive. A simple handheldreceptor, made from standard parts or easily manufactured parts, has notbeen available to a facility that is otherwise forced to use manyaerosol cans, or expensive equipment that is not cost effective. Such ahandheld receptor is the object of this invention, through a model thatdispenses a liquid which is not prone to clog the nozzle on theactuator, as well as a model that provides a simple purging mechanism,for use with paints and other liquids which have a tendency to clog theactuator.

SUMMARY OF THE INVENTION

The invention features a handheld body incorporating an actuator thatwould be found on any aerosol spray can. By utilizing a standard partincorporated in aerosol spray cans, maintenance costs and manufacturingcosts are minimized. In one embodiment, a purge capability is providedso as to preserve the usefulness of the actuator by blasting out anymaterial that might harden when contact is made with the atmosphere,such as when paint is dispensed. Different spray patterns are easilyachieved by replacing the cylindrical actuator button component of thespray actuator.

One of the main advantages of the invention is the reduction ofdiscarded standard aerosol cans, and the hazardous material they oftencontain. When traditional aerosol cans clog, either due to the actuatorclogging with dirt or dried liquid, such as paint, or due to thevertical valve clogging—the consumer often discards the can and whatevercontents remain in the can.

BRIEF DESCRIPTION OF THE DRAWINGS

FIG. 1 shows a perspective view of the preferred embodiment, viewed froma point above, to the side, and to the front of the invention.

FIG. 2 shows a perspective of an explosion view of the parts that makeup the preferred embodiment.

FIG. 2 a shows a top view of the preferred design for the insert.

FIG. 2 b shows a perspective view of the preferred design for insert.

FIG. 3 shows a cross section explosion view of the invention, taking across section as viewed from the front of the invention.

FIG. 4 shows a cross section of the assembled invention, excluding thepistol grip and the intake tubing attachment apparatus.

FIG. 5 shows a cross section viewed from the front, prior to theinsertion of plugs.

FIG. 6 a shows a view from the side, prior to the insertion of plugs. Aview of the other side is symmetrical and identical.

FIG. 6 b shows a view from the top, prior to the insertion of plugs.

FIG. 6 c shows a view from the bottom, prior to the insertion of plugs.

FIG. 7 a shows a needle valve assembly in the closed position.

FIG. 7 b shows a needle valve assembly in the open position.

FIG. 8 shows the needle valve assembly with a detente in place, toprevent the inadvertent removal of the needle valve stem from the valve.

FIG. 9 shows an embodiment of the invention which has but one inlet.

FIG. 10 shows a cross section of the body of the simplified embodimentwith one inlet.

FIG. 11 shows a perspective isometric of the simplified embodiment ofthe invention, to include the grip assembly.

FIG. 12 shows a perspective explosion view of the preferred embodiment,to include the grip assembly and intake attachment assemblies.

DETAILED DESCRIPTION OF THE INVENTION

The preferred embodiment of the invention is shown in FIG. 1. Thehandheld receptor 1 features a pistol handle assembly 2 which has apistol handle trigger 3, which, when operated with the index finger ofan operator presses the actuator 12 downward, releasing a spray ofmaterial dispensed by the handheld receptor 1. A cylindrical shapedreceptor body 5 utilizes a needle valve assembly 6 on opposite sides tocontrol the flow of propellant entering through an inlet propellanttubing 8 through a tubing connector assembly 7, or controls the flow ofdispensed liquid fed to the handheld receptor 1 through the dispensingliquid tubing 9 through a tubing connector assembly. An valve lockingring 4 holds the vertical action valve assembly to the receptor body 5.Two flat surfaces 26 are provided to assist in securing the cylindricalreceptor body 5, by means of a wrench or vise, so as to tighten thethreaded tubing connector assemblies 7 to the receptor body 5. In thepreferred embodiment the pistol handle assembly 2 is a commerciallyavailable product constructed of plastic, the vertical action valveassembly 11 is a standard part as would be employed in the manufacturingof traditional aerosol spray cans, the seals 13, 16 are of a materialappropriate for the liquid being dispensed. For dispensing paint, abutyl material is preferred; for brake cleaner and penetrant, a bunaseal is preferred; Teflon works well for many other liquids, and rubberseals are appropriate for some liquids. The tubing 8, 9 is acommercially rated Teflon FEP (fluorinated ethylene propylene), and theremaining parts are machined aluminum. Any material that is eithermachinable or moldable could be employed to construct the handheldreceptor 1, e.g. plastic, brass or stainless steel.

The purging model of the handheld receptor 1 permits the operator toclose the needle valve assembly 6 that provides a flow of liquiddispensed, such as paint, and by opening the opposite needle valveassembly 6, force air or a propellant through the vertical valveassembly 11 and actuator 12 thereby clearing any material from thevertical valve assembly 11 and the actuator 12, thereby eliminating theneed to clean the vertical valve assembly 11 and the actuator 12. Whenthe handheld receptor 1 is used in conjunction with a tank thatdispenses liquid under pressure, using gas compressed to serve as apropellant, the two feed lines to the handheld receptor 1 provide anintegrated solution.

FIG. 2 depicts an exploded view of the handheld receptor 1, without thepistol handle assembly 2. A receptor body 5 incorporates an verticalaction valve assembly 11 which provides a actuator 12 for dispensingliquids. An insert 10 provides a ridge for attaching the pistol handleassembly 2.

The insert 10 and vertical action valve assembly 11 are held in placewith the valve locking ring 4. The receptor body 5 may be heldstationary by means of two parallel flat surfaces 26 secured with atraditional wrench or vise, permitting the tubing connector assemblies 7to be secured by means of a threaded end to the receptor body 5. Thevalve locking ring 4 should be hand tightened. Two tubing connectorassemblies 7 provide for the secure attachment of tubing that suppliespropellant for purging the vertical valve assembly 11 and actuator 12,and liquid to be dispensed through the actuator 12. Needle valvescomprise a needle valve seal 13 that prevents leakage from the receptorbody 5, a needle valve seat 14, a detente pin 15 which prevents theneedle valve stem 17 from being removed completely from the needle valveseat 14, a needle valve stem seal 16 that prevents leakage from theneedle valve seat 14, and the needle valve stem 17.

FIG. 2 a shows a top view of the insert 10, showing two straight edges10 a which are parallel and opposing to one another, so as to provide alip for attaching an optional pistol handle assembly 2. When inserted,the pistol handle assembly 2 is inserted into the elongated openingdefined on the sides by the two parallel edges on the insert 10, andonce inserted, the pistol handle assembly is twisted a quarter turn sothat the pistol handle assembly is pointed in a direction that isperpendicular to the two parallel edges in the insert 10.

FIG. 2 b shows a perspective view of the insert 10. with a cross sectionselected from a point on the insert 10 that defines the end of the slotinto which the optional pistol grip assembly 2 would be first inserted,or from which the pistol grip assembly 10 would be removed. In thepreferred embodiment of this insert design, the outer diameter is 1.15inches, the diameter of the inner circular opening is one inch, thestraight edges are eight tenths of an inch apart, and the insert is0.025 inches thick.

FIG. 3 depicts a cross-section, exploded view of the handheld receptor1, without the pistol handle assembly 2. A receptor body 5 incorporatesan vertical action valve assembly 11 which provides a actuator 12 fordispensing liquids. An insert 10 provides a ridge for attaching thepistol handle assembly 2. The insert 10 and vertical action valveassembly 11 are held in place with the valve locking ring 4. Valvescomprise a needle valve seal 13 that prevents leakage from the receptorbody 5, a needle valve seat 14, a detente which prevents the needlevalve stem 17 from being removed completely from the needle valve seat14, a needle valve stem seal 16 that prevents leakage from the needlevalve seat 14, and the needle valve stem 17. Two threaded tubingconnector receptors 18 permit the attachment of tubing connectorassemblies 7, which are shown in FIG. 2.

FIG. 4 depicts a cross section of an assembled handheld receptor 1. Twothreaded tubing connector receptors 18 permit the attachment of tubingconnector assemblies 7, which are shown in FIG. 2. A receptor body 5incorporates an vertical action valve assembly 11 which provides aactuator 12 for dispensing liquids. The vertical action valve assembly11 is held in place with the valve locking ring 4. Two valve assemblies6 provide control of the liquid to be dispensed and the purging gas.

FIG. 5 depicts a cross section of a receptor body 5 with a number ofbores that facilitate the flow of liquid or purging gas within thereceptor body 5. These bores are created with a drill or other removaltool, or are incorporated into a mold to prevent material from fillingthe spaces. Two valve access bores 19 are created from the top of thereceptor body 5, stopping when they reach the feed bore 21. The feedbore 21 traverses the receptor body 5 from one side to the other,passing through a point in the center of the cylindrical receptor body 5when viewed from the top. Two smaller valve bores 20 create a channelfor material to flow from an open needle valve assembly 6 through thefeed bore 21 and into the cavity substantially filled by the verticalaction valve assembly 11. Two transfer bores 22 are created by drillingfrom the bottom of the receptor body, in two parallel paths, and carrymaterial from the bottom of the receptor body 5 to the valve assemblies6. Two inlet traverse bores 23 are produced by drilling from the outsidesurface of the cylindrical receptor body, stopping when they reach thetransfer bore 22. Two connector bores 24 are made from the bottomsurface of the receptor body 5, stopping when they reach the inlettransverse bore 23. The connector bores 24 are enlarged and machined toform a threaded tubing connector receptor 18 for the liquid to bedispensed and the purging gas. Tapered plugs are inserted into thevarious bores in order to form a receptor body 5 as depicted in FIG. 4.The tapered plugs are trimmed to a length that will not impede any rightangle flows of liquid or gas within the receptor body 5, and are pressedin place with a machine press that exerts three thousand pounds persquare inch of pressure upon each plug.

FIGS. 6 a, 6 b, and 6 c show a side, top, and bottom view of thereceptor body 5. FIG. 6 a shows a side view in perspective, and depictsthe feed bore 21 and one of the inlet transverse bores 23. Both the feedbore 21 and the inlet transverse bores 23 are plugged with taperedplugs, inserted under pressure. FIG. 6 b shows a top view, and depictsthe connector bores 24 prior to plugs inserted. FIG. 6 c shows a bottomview of the receptor body 5, and shows the threaded tubing connectorreceptors 18 that are enlarged after the connector bores 24 are created.The transfer bores 22 are machined and then plugged with tapered plugs.The two flat surfaces 26 are depicted, which permit the cylindricalreceptor body 5 to be firmly held with a wrench or vise.

FIGS. 7 a and 7 b show the needle valve assembly 6 in an open and closedposition. FIG. 7 a depicts the needle valve assembly 6 in a closedposition. The needle valve assembly 6 is placed in this position byturning the needle valve stem 17 clockwise until the needle valve stem17 seats firmly in the needle valve seat 14. A needle valve stem seal 16prevents leakage of the controlled material from the needle valveassembly 6. FIG. 7 b shows the needle valve assembly 6 in an openposition. The needle valve assembly 6 is places in this state by turningthe needle valve stem 17 in a counter-clockwise direction.

FIG. 8 shows the needle valve assembly 6 in an open position, whereinthe needle valve stem 17 is prevented from disengaging from the needlevalve seat 14 by means of a detente pin 15 which restricts the path ofthe needle valve stem 17. A valve transfer bore 25 permits the flow ofmaterial to leave the needle valve assembly 6 when the needle valveassembly 6 is in an open position.

FIG. 9 depicts the simplest embodiment of the handheld receptor 1. Areceptor body 5 incorporates an vertical action valve assembly 11 heldin place by an valve locking ring 4. FIG. 10 depicts the receptor body 5for this minimal implementation, with a threaded tubing connectorreceptor 18 shown that provides a liquid to be dispensed which does notrequire that the actuator 12 be purged. A solvent, for example, willevaporate and not clog the actuator 12, if left in the actuator 12 afteruse.

FIG. 11 depicts a non-purging version of the handheld receptor 1. Anoptional pistol handle assembly 2 is attached to the handheld receptor 1by means of an insert 10. The insert 10 and vertical action valveassembly 11, which includes a actuator 12, and is attached to thereceptor body by means of an valve locking ring 4. A tubing connectorassembly 7 mechanically attaches a tubing supplying a liquid underpressure to the handheld receptor 1. Two parallel flat edges provide ameans of firmly gripping the receptor body 5 when the valve locking ring4 is tightened.

FIG. 12 depicts a perspective isometric view of the preferredembodiment, with the optional pistol handle assembly 2 in place. Areceptor body 5 incorporates an vertical action valve assembly 11 whichprovides a actuator 12 for dispensing liquids. An insert 10 provides aridge for attaching the pistol handle assembly 2. The insert 10 andvertical action valve assembly 11 are held in place with the valvelocking ring 4. The receptor body 5 may be held stationary by means oftwo parallel flat surfaces 26 secured with a traditional wrench or vise.Two tubing connector assemblies 7 provide for the secure attachment oftubing that supplies propellant for purging the actuator 12, and liquidto be dispensed through the actuator 12. Valves comprise a needle valveseal 13 that prevents leakage from the receptor body 5, a needle valveseat 14, a detente which prevents the needle valve stem 17 from beingremoved completely from the needle valve seat 14, a needle valve stemseal 16 that prevents leakage from the needle valve seat 14, and theneedle valve stem 17.

1. A handheld receptor consisting of a cylindrical receptor body with athreaded upper end, a commercially available vertical action valveassembly, and a valve locking ring, said valve locking ring threaded tomate with said threaded upper end of said receptor body, and having anopening through which said vertical action valve may extend, configuredso that when said valve locking ring is tightened to said threaded upperend of said receptor body, said vertical action valve is seated firmlyto said receptor body, said receptor body configured to receive saidvertical action valve into a chamber that is configured to receive saidvertical action valve with a minimum of space and volume between saidvertical action valve and said receptor body, said receptor body havinga bore through the center of said cylindrical receptor body from the topto the bottom flat surface, through which a liquid material may besupplied under pressure and dispensed by an operator, through theactivation of an actuator on said vertical action valve assembly. 2.(canceled)
 3. A handheld receptor as in claim 1, wherein an insert isplaced between said vertical action valve and said valve locking ring,(a) said insert having a cylindrical portion configured to fit snuglywithin the well of said vertical actuator valve and having an outer lipand an inner lip, (b) said outer lip extending outward from saidcylindrical portion and resting on the top cylindrical surface of saidvertical action valve so as to secure said insert on top of saidvertical action valve, (c) said inner lip extending inward so as to forma lip suitable for attaching a spray nozzle assembly, said inner lip andsaid outer lip presenting a flat surface when viewed from above, (d)said inner lip defining a circular opening modified by two extendededges which define two straight opposing edges, said straight edgesproviding a front and back edge for securing said spray nozzle assemblysecurely to said handheld receptor, (e) said spray nozzle assemblyattaching to said handheld receptor by inserting said spray nozzleassembly into the elongated opening defined by said insert, andthereafter rotating said spray nozzle assembly one quarter turn, so thatthe front and back edges of said spray nozzle assembly grip to the lipsdefined by the straight edges of said insert.
 4. A handheld receptor asin claim 1, wherein an insert is placed between said vertical actionvalve and said valve locking ring, (a) said insert having a flat upperand lower surface, parallel to one another, and a circular outer edge,of a diameter which fits snugly within said valve locking ring, saidinsert having an inner opening consisting of two circular edges of adiameter that is slightly larger than that of the crimped edge of anaerosol can, said circular edges being opposite of one another and eachoccupying approximately ninety degrees of said opening, (b) said inserthaving two straight edges connecting said circular edges one to another,providing a narrower opening suitable for gripping by an external pistolgrip assembly, when said pistol grip assembly is inserted parallel tosaid straight edges and thereafter twisted ninety degrees.
 5. A handheldreceptor as in claim 1, wherein said receptor body is comprised ofmachined aluminum, machined brass, or injection molded plasticmaterials, said injected molded part being molded in two parts andthereafter assembled.
 6. (canceled)
 7. (canceled)
 8. A handheld receptoras in claim 1, for which a tubing connector assembly is threaded andinserted in the bottom of said handheld receptor body, in a femalethreaded seat configured to provide a tight and leakproof seat,configured to provide a tight mechanical coupling to an inlet tube thatsupplies liquid material to be dispensed.
 9. (canceled)